Structural material and process of making the same



' sure complete reaction,

will, without destroying the essential Water the desired material.

Patented Sept. 20, 1932 UNITED STATES PATENT OFFICE HARRY G.

DIANA, ASSIGNORS TO ROSTONE, CORPORATION OF INDIANA.

STRUCTURAL MATERIAL rm rnoonss No Drawing. 1

This invention is an improvement upon or the making of the materialrostone therein set forth,'we employ as essential raw materials (a) amineral substance, such as slate, shale, and certain clays composedwholly or in part of aluminosilicic acid; (b) lime, magnesia, or otheralkaline earth base, and (0 water as an essential reacting agent. Inproducing such artificial structural material the alkaline earth baseand finely ground mineral are mixed with sufiicient water to enand henso heated as content of the mass, transform the mass by reaction into aproduct possessing high compressive and tensile strength and resistantto attack by ordinary chemical reagents. The optimum the mass forproducing the desired reaction is approximately 25% (based on the dryweight of the solid constituents) as set forth in said application. 3

Such a mixture can be subjected to heat, in presence of water vapor, tocause the desired reaction between the base, aluminosilicic acid andwater and produce the desired product. Or such mixture can be induratedwith steam at substantially atmospheric ressure until the mass istransformed into While steam is preferably employed other agencies areeifective as recited in said application. As described in saidapplication good induration was obtained by the use of steam pressuresas low as atmospheric with corresponding temperature of substantially212 F. but when heating counter current the steam could be held to anydesired temperature, dictated by varying ZPEFFER, RICHARD L. HARRISON,AND DAVID E.

IncoaronA'TIm, or LAFAYETTE, INDIANA, A

Application filed September 22,

amount of water necessary in BOSS, or IAFAYETTE, m-

or MAKING- THE SAME 1930. Serial 1%. 4 3,747.

composition in the raw materials, but avoid in high pressure; preferablyusing only su 'cient pressure to secure good circulation. We havediscovered that coarse aggregates of'various kinds-such as rock, stone,gravel and other hard aggregates, and particularly Indiana limestone andthe like, or broken pieces of rostone,-can be mixed with the aforesaidraw materials prior to induration. thereof; and when so mixed and themass 1n-' aggregate by and a subdurated as described the coarse will beintimately bound together with the rostone and form therewith Istantially homogeneous structure or body in which the coarse aggregateisclosely bound by the rostone and so inseparably connected therewithand thereby that if the mass-should be fractured thefracture would takeplace through the aggregates as well as through i the rostone, and theaggregate cannot separate from the rostone.

By our invention an duced which can be molded into shapes If desiredbefore induration, or which after in duration can be chiseled, sawed ortooled; and it can be colored or tinted before induration, and willpreserve the color after indura- In carrying out our process wepreferably mix the alkaline earth base, aluminosilicic acid material andcrushed aggregate, then add the optimum amount of water, thoroughly mixthe same, and then indurate it in the manner above suggested.

As an example; to produce an artificial artificial stone is prostoneusing Indiana limestone as the coarse aggregate, the followingproportions of Inv.

gredients have been successively used:

22 parts of base material.

parts of aluminosilicic acid parts of crushed Indiana limestone (passingthrough-a 14 mesh screen, but retained on a 100 mesh screen) and 22parts of water. 7

The base, aluminosilicic acid material and tial reacting water until themass is transaggregate should be first thoroughly mixed, formed into thedesired material.-

t en the water added, and then the mass 6. The herein describedartificial strucmolded and indurated as set forth in our tural materialpossessing high compressive 5 aforesaid application. The resultantprodand tensile strength; produced by mixing an 70 not is a structuralmaterial in which the agalkaline earth base, a finely ground mineralgregate is intimately and inseparably bonded material containinghydrated aluminosilicic with and by the rostone. acid, a coarseaggregate, and water in opti- Before induration the mass may be moldedmum quantity to produce complete reaction; I

or otherwise formed into suitable shapes, as and heating the mass Whileretaining its es- 75 in ordinary ceramic practice, and then hardsentia-lWater content until it is transformed ened or indurated as set forth inour aforeinto the desired product. said application. 7. The hereindescribed artificial struc- Ve claim: tural material possessing highcompressive 1. The process of producing an artificial and tensilestrength; produced by mixing an 30 structural material; consisting inmixing an alkaline earth base, a finely ground material alkaline earthbase, a finely ground mineral composed principally of hydratedaluminomaterial containing hydrated aluminosilicic silicic acid, acoarse aggregate, and Water; acid, a coarse aggregate, and water inoptiand subjecting the mass to heat in presence mum quantity to producecomplete reaction; of Water vapor to prevent evaporation of 85 andheating the mass While retaining its esessential reacting water untilthe mass is sential Water content until it is transformed transformedinto the desired material. into the desired material. 8. The hereindescribedv artificial struc- 2. The process .of producing an artificialtural material possessing high compressive structural material;consisting in mixing an and tensile strength and having a bindingalkaline earth base, a finely ground material medium resistant to attackby ordinary chemcomposed principally of hydrated aluminoical reagents;produced by mixing an alkae silicic acid, a coarse aggregate, and Water,in line earth base selected from a group conproportions to produce amaterial possessing sisting of lime and magnesia, a finely ground highcompressive and tensile strength; and material composed principally 'ofhydrated 95 subjecting the mass to heat in presence of aluminosilicicacid, a coarse aggregate, and Water vapor to prevent evaporation ofessen- Water; and subjecting the mass to heat while tial reacting wateruntil the mass is transretaining the essential reacting Water untilformed into the desired material. the mass is transformed into saidmaterial.

3. The herein described process of pro- 9. The herein describedartificial strucducing an artificial structural material posturalmaterial possessing high compressive sessing high compressive andtensile strength and t nsile Strength; produced by mixing an and havinga binding medium resistant to alkaline earth base selected from a groupattack by ordinary chemical reagents; conconsisting of lime andmagnesia, a finely sisting in mixing an alkaline earth base se-' groundmaterial composed principally of hy- 105 leoted from a group consistingof lime and dratedaluminosilicic acid, a coarse natural magnesia,afinely ground'material composed stone aggregate, and water, inproportions principally of hydrated aluminosilicic acid, a to producethe material; andsubjecting the arse aggregate, and water; andsubjecting mass to heat in presence of water vapor to the mass to heatwhile retaining the essential prevent evaporation of essential reactingreacting Watentherein until the mass is trans- Water n il the m ss stransformed. formed into said material. 10. The herein describedartificial struc- 4. The herein described pro s of protural material;produced by mixing an alkaducing an artificial structural material;con-' linel base, finely g und m eri l C0111- sisting in mixing analkaline earth base, and PQ P p y of hydrated aluminosilicic a finelyground material composed princi- @cld, d r aggregate; addmg Water pallyof hydrated aluminosilicic acid, adding 111 QP V, Produce complete acoarse aggregate and water to the mass, acttoni and f sublectmg h massto b .5 and subjecting the massfio heat until it is until the mass 1stransformed into the desired 11. The herein described artificialstructural material possessing high compressive and. tensile strengthand having binding 5. The herein described process of producing anartificial structural material; consistm mlxlng an aumhne earth 9 amedium resistant to attack by ordinary chemfinely ground mammal qmp i pical reagents; produced by mixin an alka 125 ly of hydra'edalunnnosllicic 301d, adding li earth b Selected f a (from? com a Coarsegg then addlng Suflicient sisting of lime and magnesia,afin ely groundwater to the mass to cause complete reaction, material composedprincipally of hydrated and subjecting the mass to heat in presence ofaluminosilicic acid, and a coarse aggregate;

water vapor to prevent evaporation of essenadding water to the mixture,and finally sub- 130 transformed into the desiredmaterial. material Iname jecting the mass to heat and retaining the essential reacting wateruntil the mass is transformed into said material.

12. The herein described artificial structural material resistant toordinary chemical rea ents; produced by mixing an e mi base, a finelyound mineral material containing hydrat aluminosilicic acid and a coarseaggregate, adding thereto suflicient water to cause complete reaction,and finally indurating the mas with steam at substantially atmosphericis transformed into the said material.

. HARRY C. PEFFER.

. RICHARD L. HARRISON.

DAVID E. BOSS. i

pressure, until the mass

